Layered modular constructs and processes therefor

ABSTRACT

Modular constructs are disclosed wherein a plurality of structural members, most often parallel to one another, form spaced-apart layers. Clamping force, applied in some embodiments approximately perpendicularly to a face of each structural member through use of one or more tension assembly comprising a cable, rope, wire, rod, or the like, in association with one or more tubular spacer, is used to draw the structural members into alignment and to provide structural integrity of the modular construct. The subject matter of the present disclosure further relates to processes for creating such layered modular constructs. The subject matter of the present disclosure may find particular application within modular structures, such as, but not limited to, those for aircraft, boats, and other means of transportation, buildings, storage spaces, furniture and cabinetry, modular support systems for electronic equipment, support structures, interfaces, prosthetics, rack systems, modular work partitions, and the like.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of, and claims priority to,U.S. non-provisional patent application Ser. No. 14/137,290 filed onDec. 20, 2013, entitled “Layered Modular Constructs and ProcessesTherefor,” now U.S. Pat. No. 9,352,836 issued on May 31, 2016, whichclaimed priority to U.S. provisional patent application No. 61/740,763,filed Dec. 21, 2012, also entitled “Layered Modular Constructs andProcesses Therefor,” the entire contents of which are incorporatedherein by reference.

TECHNICAL FIELD

The subject matter of the present disclosure relates, generally, tomodular constructs and to processes for modular construction. Moreparticularly, the subject matter of the present disclosure relates tolayered modular constructs, and to processes for creating them, whereinclamping force is applied via cable, rope, wire, rod, or the like, inassociation with one or more tubular spacer, to draw spaced-apartstructural members into alignment and to provide structural integrity ofthe modular construct.

BACKGROUND

As a structural design premise, form should always serve function. Oneexplanation of this design premise is that the form of a structureshould enhance, and not interfere with, or detract from, the function ofthe structure in view of its intended purpose and/or use. The samepremise should apply, equally, to any smaller component, structure, orelement affixed to and/or carried by the structure; as well, to anylarger structure to which the structure is affixed and/or which willcarry the structure.

While this design premise may be aspirational, it is observably notfollowed in many structural designs. This is not necessarily the faultof the designer, in that modern design philosophy has tended to besomewhat myopic, focusing on traditional design, manufacturing,fabrication, construction, and assembly techniques.

For example, modern modular constructs, and associated processestherefor, are most often premised upon box-like structures—rectangularstructures comprising panel-like members exhibiting perpendicularsurfaces. Load-carrying members of such structures typically are joinedin perpendicular arrangement. That is, structural, load-carrying,panel-like members are most often joined or attached either at therespective ends of two perpendicularly arranged members, as in an“L”-shaped configuration, or at an end of one member and along a flatsurface of an adjacent member perpendicular thereto, as in a “T”-shapedconfiguration.

In a significant number of applications, such box-like structures, andtheir resulting modular constructs, may be suboptimal for any of avariety of reasons.

For illustration, one might turn to a particularly exemplary applicationdrawn generally from the cabinetry arts, as specifically applied in thefield of private aircraft interior design and construction. In such anapplication, internal or interior modular structures, such as cabinetryfor installation within an aircraft galley, must meet a variety offunctional and service requirements, along with Federal AviationAdministration (FAA) regulations, flight-based technical specifications,and design constraints. One might appreciate that, while such modularstructures must provide functionality similar to that provided by theirconventional, ground-based counterparts, they must do so within anunconventional, difficult environment.

As might be apparent, internal or interior modular cabinet structuresfor aircraft galleys of the type described often function to support andhold coffee machines and other small appliances, glassware, tableware,flatware, serving pieces, wine bottles, drink containers, and a varietyof foodstuffs. They provide countertop and working spaces. They providedrawer and storage spaces. They may be configured with sink, watersupply, and drainage systems. They are typically wired for illuminationand electrical service. They may have computer or other electronicinterfaces. In private aircraft of the sort described, they often arefinished with high-end, aesthetically pleasing surfaces.

And yet, while serving the conventional functions described above,aircraft internal or interior modular structures must fit and operatewithin an extremely tight, carefully allocated space. Not only must theysupport the above-described contents, as their ground-based counterpartsmust do, they must, further, safely constrain those contents against thevibrations and stresses arising during ground and flight-basedoperations. Uniquely, and as typically required by the laws andregulations of one or more countries, they must be designed,manufactured, tested, certified, and installed to meet the rigors of theaircraft industry.

For example, they must be fire resistant. They must be permanentlymarkable, and marked, with identifying indicia sufficient to providemanufacturing traceability in the event of an in-air/in-serviceaccident. They must be capable of withstanding significant gravitation,torsion, vibration, pressurization, and other forces. And they must becapable of withstanding those significant forces throughout long servicecycles, often measured in tens of years, without degrading or failing.They must be quiet in the face of vibration, pressure changes, and otherin-service stresses and strains to which they are subjected. They mustbe insulated against those routine, but extreme, temperaturefluctuations to which an aircraft is subjected. They must, of course, belightweight so as to reduce aircraft fuel consumption and, thereby, toincrease operational range. For installation and service, they must fitthrough the relatively small entrance hatch of an aircraft. Thisrepresents, of course, only a small sampling of the many considerationsattendant such aircraft internal or interior modular structures.

Notwithstanding the extreme environments, requirements, and constraintsto which such aircraft internal or interior modular structures aresubjected, they continue—disadvantageously—to be designed, manufactured,and assembled as high-tech, box-like structures. The followingdiscussion seeks to convey an understanding of why such a box-likestructure is disadvantageous with regard to the exemplary aircraftinternal or interior modular structures under consideration.

In order to meet the significant stresses to which they are subjected,while remaining lightweight for the reasons described above, aircraftinternal or interior modular structures are constructed usinghoneycombed-aluminum laminate materials. While these materials arelightweight, they are relatively expensive. Additionally, theirprincipal strength lies along the length of the material. Across thethickness of the material, it is easily pierced, punctured, and crushed.This is, of course, not preferable, since manufacturing, assembly,packaging, transport, and installation processes must be carefullyestablished to ensure that the honeycomb material is not damaged.Additionally, and by their very nature, such honeycombed, laminatedmaterials are of non-uniform density and non-uniform strength; i.e., thecenter of each honeycomb is less dense and less strong than thesurrounding cell wall. Thus, it should be relatively apparent that whentrying to form L-joints and T-joints of the type most often used inconstructing box-like modular structures, ordinary fasteners, such asscrews, bolts-and-nuts, nails, and the like, are of little value.

Rather, and long ago, the aircraft industry adopted the use of panelpins and adhesives to join load carrying panel members. With suchconstruction, a panel pin is embedded between panel members, typicallywithin and between adjacent cells forming the honeycomb material of eachpanel, and the panel pin is adhered in-place through the use ofhigh-fill adhesives and/or resins. As might be expected, this is anexpensive, intensive, by-hand process, requiring custom clamps,fixtures, and/or jigs to hold the panels in fixed and appropriaterelative orientation over the extended adhesive drying and cure timesrequired.

Additionally, it will be appreciated that further use of adhesives,resins, and edge-fill products are required to form appropriatelyfinished edges along any honeycombed material that has been cut. This,too, is an expensive, intensive, by-hand process, requiring extendeddrying and curing times.

Of course, once the aluminum honeycombed materials have been joined intoa desired structure, they typically are overlaid, by hand, withappropriate finish materials. This portion of the aircraft internal orinterior modular structure construction process typically requiresfurther clamps, fixtures, jigs, tools, and techniques appropriate to thefinishing task. Similarly, long drying and cure times are required.

As can easily be seen from this description, design and productioncycles are long, requiring highly-skilled and experienced personnel.Repeatability between similar modular structures is often difficult, dueto the nature of the by-hand processes. If in-process error or damageoccurs, the modular structure often can be repaired only with greatdifficulty, or sometimes cannot be repaired at all, since joints areadhesively bonded. In any event, extreme care must be taken during anyattempted repair or the modular structure may be further damaged.

For the same reasons, should a change order be entered for an existingaircraft internal or interior modular structure, such as may benecessary to upgrade or replace an appliance, or should the owner wishto reconfigure a galley space, for example, to add an appliance, toreconfigure storage spaces, or to modify galley functionality, theexisting modular structure most often must be scrapped.

All the while, during this extensive and time-consuming process, anaircraft may lay dormant and out-of-service for weeks or months. Whenthe aircraft internal or interior modular structure is finally ready forinstallation, it certainly cannot be transported to the aircraft andassembled in-situ; rather, the aircraft typically is flown to anaccredited, well-tooled facility—which is most often remote from theaircraft owner's facility—where the aircraft internal or interiormodular structure must be installed by specialized, highly-skilled, andexperienced personnel.

Thus, as may be seen from the above description, manufacturing of suchbox-like modular constructs is time consuming and skilled-laborintensive, even when the design of the aircraft internal or interiormodular structure is repeated over many units. There are fewmanufacturing efficiencies to be recognized. The process is heavilydependent upon a variety of clamps, fixtures, and/or jigs. Panel pins,along with adhesives, resins, and edge-fill products of differing types,specifications, and uses are required, with associated long drying andcure times. Configured spaces cannot easily be reconfigured withoutdemolishing and rebuilding the entire structure, or a significantportion thereof. Even when such reconfiguration is possible, it may onlybe achieved through labor and material-intensive processes.

One might argue that advanced technologies, such as precision computernumerically controlled water jet cutting, plasma cutting, laser cutting,and the like, in combination with advanced, engineered materials of thetypes discussed above, are capable of producing customized, intricatelyshaped, flat panels at much higher speeds and throughputs than have beenpreviously possible. While it is true that significant advances havebeen made in the types and precision of machines for the manufacture,fabrication, and assembly of parts, as well as significant advances incomputerized design and manufacturing systems, as well as significantadvancements in materials science, such advancements have most oftenbeen applied merely to increase the speed with which panels can beproduced, and to increase individual-part dimensional accuracy, ratherthan being exploited to enable a true paradigm shift in the design ofthe modular structure itself. That is to say, notwithstanding thetechnological advancements described above, modern structural designphilosophy has not heretofore recognized that such advancements may beused to enable the “form should always serve function” design premise;and, thereby, to take advantage of the many accompanying benefits.Rather, it is still most typical that modular constructs are designedand built as box-like forms.

Notwithstanding the above, even when considering human interface factorsand ergonomics, box-like modular constructs of the type described aredemonstrably suboptimal. Especially within the extremely tight,carefully allocated space of an aircraft galley, a box-like structure isintrusive, in that such structures are inherently bulky andspace-monopolizing. Because available space is already tight, humaninterfaces become even more cumbersome: consider the space necessary toopen a drawer or cabinet, and how the person opening that drawer orcabinet must position his or her body within the limited, availablespace to accommodate that function. Consider, also, how much of thepreferred human envelope space—and its reasonably-required, associatedfunctional space—is subordinated to the boundaries of the box-like form.

Furthermore, with box-like forms, adjacent spaces do not flow togethernaturally; rather, they are interrupted by the aesthetically unpleasingsharp corners and edges of that form. Additionally, such forms are notwell-suited to the natural curvature of the human body—many injuriesoccur when persons attempt to move through tight spaces fitted withsharp-cornered, sharp-edged forms. And this is only exacerbated forhigh-mounted box-like forms.

In fact, with a box-like construct, the user must adapt to the space andmodular configuration provided, rather than the space and modularconstruct supporting the user's functional and ergonomic needs. Ifconsidered honestly, one would conclude that this is not how a usershould be required to interact with a workspace—or any other space. Thatis to say, in such suboptimal, conventional, prior art structures,function must adapt to meet the provided form, rather than the providedform being adapted to meet the necessary or desirable function, as wasposited at the outset to be the aspirational design premise.

Although the aircraft internal or interior modular structure describedabove was chosen to illustrate certain deficiencies in use of thebox-like form, there are numerous exemplary modular constructs to whichthe “form should always serve function” design premise might beextended. Such modular constructs may be seen with reference to any of avariety of modes of transportation, such as aircraft, boats, trains,trucks, equipment trailers, and personal vehicles; and to many of theliving, storage, or support spaces attendant such modes oftransportation. Such modular constructs may be seen with reference tobuildings, wherein forms such as walls, fenestrations, and ancillarystructures associated with the buildings may be found. Such modularconstructs may be seen with reference to structures internally housed bybuildings, wherein forms such as supports, platforms, and storage areasare required. Such modular constructs might also be seen with referenceto specialty structures, such as prosthetics for human use, supports forelectronic equipment, platforms for solar panels, rack systems, modularwork partitions, and the like.

Accordingly, in considering the “form should always serve function”design aspiration set forth at the outset of this discussion, adesirable solution to the above-described deficiencies in the prior artmodular constructs and related processes would allow one, in appropriatecases, to avoid the construction of box-like structures. Rather, such asolution would allow a designer to specify a modular construct thatbetter enables a user to gain access to and operate withinparticularized functional parameters, without hindrance by bulky andspace-monopolizing structures.

Such a solution would minimize or eliminate joinder of structural panelsin “L” or “T”-shaped configurations. Such a solution would also minimizeor eliminate the need to use advanced, expensive, honeycomb materials,while providing for use of materials having appropriate mechanicalproperties along length and across thickness, at the same timeminimizing the required thickness—and, therefore, the weight—of suchmaterials, and, at the end, providing a significantly stronger, yetlighter structure with conventional, relatively lower cost materials.

A desirable solution, further, would reduce or remove the need for useof conventional pins, fasteners, adhesives, bonding agents, edge-fillproducts, and the like. Of course, without the use of conventionalfasteners, such a solution would allow a modular construct to be morerapidly assembled, with a minimal number of required tools, and withoutcustom clamps, fixtures, and/or jigs to hold the panels in fixed andappropriate relative orientation during the assembly process.

A desirable solution would reduce design and production cycles. It wouldreduce the need for highly-skilled assemblers. It would allow forrepeatability between similar modular structures. If in-process error ordamage should occur, the modular structure could be easily andinexpensively repaired. Post-delivery or post-hoc reconfiguration andmodification could more easily be handled, and with significantly lessexpense and downtime. Importantly, a desirable solution would allowconvenient and relatively inexpensive transportation of unassembledcomponents of a modular construct to a desired location, whereafter themodular structure could be efficiently assembled in-situ or on-site;thereby, minimizing or avoiding extended out-of-service situations.

A desirable solution would, of course, take advantage of the manybenefits accompanying advanced manufacturing technologies, such asprecision computer numerically controlled water jet cutting, plasmacutting, laser cutting, multi-axis milling and routing, threedimensional (“3D”) printing, injection molding, and the like, whileavoiding the need for skilled, by-hand lay-up and assembly processes.

A desirable solution would enhance, not detract from, human interfacedesign and ergonomics. Rather, modular constructs built according tosuch a desirable solution would better flow into available spaces,reducing footprint and required operating space, while maintaining—orincreasing—operational performance, user comfort, and user safety.

And a desirable solution would be useful and functional when applied toany of a variety of applications.

Thus, the “form should always serve function” design premise—and adesirable solution implementing it—would provide a paradigm shift indesign, engineering, manufacturing, fabrication, construction, assembly,and/or like processes; in turn, leading to reductions in human labor,reductions in need for the wide variety of fasteners and correspondingassembly tools, reductions in assembly, manufacturing, and relatedcosts, increases in efficiency, increases indesign-to-finished-structure speed and predictability, more efficientand improved scalability, more efficient re-purposing and reconfiguringof the structure, decreased weight, increased usable space, and likebenefits. In appropriate cases, such paradigm shift in design,manufacture, fabrication, construction, and/or assembly might providestronger constructs, improved factors of safety, reductions in failurerates, tunable rigidity, flexibility, and/or vibrational dampeningwithin the modular construct, and like benefits, due to improvements inthe way load carrying parts are used, combined, aligned, attached, andintegrated into and within the structure.

Accordingly, it is to the disclosure of such modular constructs,processes for modular construction, and related systems that thefollowing is directed.

SUMMARY

The subject matter of the present disclosure relates, in variousembodiments, to modular constructs wherein a plurality of structuralmembers, most often parallel to one another, form spaced-apart layers,and wherein clamping force, applied in some embodiments approximatelyperpendicularly to a face of each structural member through use of oneor more tension assembly comprising a cable, rope, wire, rod, or thelike, in association with one or more tubular spacer, is used to drawthe structural members into alignment and to provide structuralintegrity of the modular construct.

According to some embodiments, a plurality of guiding offset rests aidsimilarly constructed, modular substructures in nesting into a primarymodular structure, wherein each modular substructure comprises aplurality of structural members most often parallel to one another,forming spaced-apart layers, interconnected via one or more tensionassembly.

Modular structures and/or substructures according to the presentdisclosure may carry one or more appliance mount, similarly constructedin layered, tensile-constrained form. Modular structures according tothe present disclosure may further carry one or more drawer assemblyand/or, in some embodiments, storage assembly, also similarlyconstructed in layered and tensile-constrained form. Additionally,modular structures according to the present disclosure may be configuredso as to removably clasp and hold items, such as glassware or stemware,through the use of one or more sliding retaining layer.

In some embodiments, selected layers may be electrically connected toand energized by a transformer or other electrical source to provideelectrical power for light features, appliances, equipment, or the like.

Appropriate structural mounts may be provided in order to removablyaffix modular structures according to the present disclosure to a floor,subfloor, footing, rail system, wall, or other support or structuralinterface.

In some embodiments, surface finishes may be applied in the form ofsnapped, clamped, magnetically or electro-magnetically attached, orpress-fit outer layers, or skins, that are easily removable andreplaceable.

Uniquely, all assemblies, subassemblies, and components are designed andconfigured to be easily assembled, tightened, loosened, anddisassembled, both by module and by individual component, through adistinctive, single side access system, which, in most embodiments,requires use of only a single, modest tool. Modular structures accordingto the present disclosure advantageously may be entirely constructed,maintained, and/or reconfigured from a single side due to the layeredstructure and design of such modular structures, in association withtension assembly-based, layer-interconnection means. Layers within eachassembly and/or subassembly are assembled in defined order inassociation with a relevant tension assembly. Upon completion ofassembly, the tension assembly conveniently may be tightened from asingle side of the modular structure, preferably making use of a singletool, such as a wrench. In some embodiments, a torque-measuring wrenchmay be utilized to assure that the modular assembly meets anypredefined, applicable performance specifications.

Further, and importantly, should any maintenance and/or reconfigurationof a modular structure according to the present disclosure be required,one need simply loosen relevant tension assemblies from a single side ofthe modular structure, and subsequently remove only those componentparts necessary to access the layer or feature of interest. One may thenrepair, maintain, replace, reconfigure, and/or the like, those componentparts of interest; thereafter, replacing subsequent component parts indefined order in association with relevant tension assemblies. Uponcompletion of reassembly, relevant tension assemblies may be retightenedfrom a single side of the modular structure.

The subject matter of the present disclosure further relates, in variousembodiments, to processes for creating such layered modular constructs,wherein a designer can evaluate the space available, the functionalrequirements for use of that space, the highest, best, and most optimalconfiguration for that space, amongst other considerations, and providean aesthetically pleasing, functionally and ergonomically superiorconfiguration of modular structure that cannot be achieved byconventional methods. The layered design and construction of modularsystems according to the present disclosure take best advantage ofmodern, high speed computer aided design and computer numericallycontrolled machinery. Parts are quickly and easily cut, identified,finished, inventoried (if desired), and the like. They can be picked andkitted from inventory, provided with assembly instructions, and quicklyassembled through use of a single modest tool, or minimal tools. Ifdesired, parts can be packaged in flat crates, shipped wherever needed,and easily assembled in situ.

The subject matter of the present disclosure may find particularapplication within modular constructs, such as, but not limited to,those for aircraft, boats, and other means of transportation, buildings,storage spaces, furniture and cabinetry, modular support systems forelectronic equipment, support structures, interfaces, prosthetics, racksystems, modular work partitions, and the like.

These, and other, features, advantages, and benefits shown by thevarious embodiments of the layered modular constructs and relatedprocesses for creating them, as set forth within the present disclosure,will become more apparent to those of ordinary skill in the art afterreview of the following Detailed Description of Illustrative Embodimentsand Claims in light of the accompanying drawing Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Accordingly, the within disclosure will be best understood throughconsideration of, and with reference to, the following drawing Figures,viewed in conjunction with the Detailed Description of IllustrativeEmbodiments referring thereto, in which like reference numbersthroughout the various Figures designate like structure, and in which:

FIG. 1 depicts an embodiment of a front elevation view of an aircraftinterior modular system, in accordance with the subject matter of thepresent disclosure;

FIG. 2 depicts a first side elevation view of the aircraft interiormodular system of FIG. 1, in accordance with the subject matter of thepresent disclosure;

FIG. 3 depicts a second side elevation view of the aircraft interiormodular system of FIG. 1, in accordance with the subject matter of thepresent disclosure;

FIG. 4 depicts a front elevation view of two tension rod assemblies anda portion of a lighting assembly contained within an upper portion ofthe aircraft interior modular system of FIG. 1, in accordance with thesubject matter of the present disclosure;

FIG. 5A depicts an edge view of a guiding offset rest for use inassociation with the aircraft interior modular system of FIG. 1, inaccordance with the subject matter of the present disclosure;

FIG. 5B depicts a plan view of the guiding offset rest of FIG. 5A, inaccordance with the subject matter of the present disclosure;

FIG. 5C depicts a partial elevation view of an upper portion of a cradleassembly of the aircraft interior modular system of FIG. 1, inaccordance with the subject matter of the present disclosure;

FIG. 5D depicts a partial elevation view of a lower portion of a cradleassembly of the aircraft interior modular system of FIG. 1, inaccordance with the subject matter of the present disclosure;

FIG. 6A depicts an alternate embodiment of a tension assembly accordingto the subject matter of the present disclosure in a released position,in accordance with the subject matter of the present disclosure;

FIG. 6B depicts the tension assembly of FIG. 6A in a locked position, inaccordance with the subject matter of the present disclosure;

FIG. 7A depicts a side elevation view of an appliance mount and bracketcontained within an upper portion of the aircraft interior modularsystem shown in FIG. 3, in accordance with the subject matter of thepresent disclosure;

FIG. 7B depicts a front elevation view of an appliance mount and bracketcontained within an upper portion of the aircraft interior modularsystem shown in FIG. 1, in accordance with the subject matter of thepresent disclosure;

FIG. 8A depicts a front elevation view of a support layer assembly ofthe aircraft interior modular system shown in FIG. 1, in accordance withthe subject matter of the present disclosure;

FIG. 8B depicts a side elevation view of the support layer assembly ofFIG. 8A, in accordance with the subject matter of the presentdisclosure;

FIG. 8C depicts an exploded side elevation view detailing each supportlayer shown in FIGS. 8A and 8B, in accordance with the subject matter ofthe present disclosure;

FIG. 9A depicts a front elevation view of a cradle layer assembly of theaircraft interior modular system shown in FIG. 1, in accordance with thesubject matter of the present disclosure;

FIG. 9B depicts a side elevation view of the cradle layer assembly ofFIG. 9A, in accordance with the subject matter of the presentdisclosure;

FIG. 9C depicts an exploded elevation view detailing each cradle layershown in FIGS. 9A and 9B, in accordance with the subject matter of thepresent disclosure;

FIG. 10A depicts a front elevation view of a cradle assembly of theaircraft interior modular system shown in FIG. 1, further illustrating asliding retaining layer assembly thereof, in accordance with the subjectmatter of the present disclosure;

FIG. 10B depicts a side elevation view of a portion of the slidingretaining layer assembly of FIG. 10A, in accordance with the subjectmatter of the present disclosure;

FIG. 100 depicts a front elevation view of a portion of the slidingretaining assembly shown in FIG. 10A, in accordance with the subjectmatter of the present disclosure;

FIG. 11A depicts a side elevation view of a support layer assembly ofthe aircraft interior modular system shown in FIG. 1, furtherillustrating an upper drawer assembly, in closed position, associatedwith the referenced support layer assembly, in accordance with thesubject matter of the present disclosure;

FIG. 11B depicts a side elevation view of a support layer assembly ofthe aircraft interior modular system shown in FIG. 1, furtherillustrating an upper drawer assembly, in open position, associated withthe referenced support layer assembly in accordance with the subjectmatter of the present disclosure;

FIG. 11C depicts an exploded side elevation view detailing each supportlayer aligned with a corresponding upper drawer assembly layer, andfurther detailing each upper drawer assembly layer, in accordance withthe subject matter of the present disclosure;

FIG. 12A depicts a side elevation view of a support layer assembly ofthe aircraft interior modular system shown in FIG. 1, furtherillustrating a lower drawer assembly, in closed position, associatedwith the referenced support layer assembly, in accordance with thesubject matter of the present disclosure;

FIG. 12B depicts a side elevation view of a support layer assembly ofthe aircraft interior modular system shown in FIG. 1, furtherillustrating a lower drawer assembly, in open position, associated withthe referenced support layer assembly, in accordance with the subjectmatter of the present disclosure;

FIG. 12C depicts an exploded side elevation view detailing each lowerdrawer assembly layer, in accordance with the subject matter of thepresent disclosure;

FIG. 13A depicts a front elevation view of the aircraft interior modularsystem shown in FIG. 1, further illustrating an embodiment of areconfigurable sectional modularity, in accordance with the subjectmatter of the present disclosure;

FIG. 13B depicts a first side elevation view of the aircraft interiormodular system of FIG. 13A, further illustrating a first side elevationview of the reconfigurable sectional modularity, in accordance with thesubject matter of the present disclosure;

FIG. 13C depicts a second side elevation view of the aircraft interiormodular system of FIG. 13A, further illustrating a second side elevationview of the reconfigurable sectional modularity, in accordance with thesubject matter of the present disclosure;

FIG. 13D depicts an exploded side elevation view detailing eachreconfigurable sectional modularity layer, in accordance with thesubject matter of the present disclosure;

FIG. 14A depicts a front elevation view of the aircraft interior modularsystem shown in FIG. 1, further illustrating an embodiment of anelectrical and lighting system for use therewith, in accordance with thesubject matter of the present disclosure;

FIG. 14B depicts a first side elevation view of the aircraft interiormodular system of FIG. 14A, further illustrating the electrical andlighting system thereof, in accordance with the subject matter of thepresent disclosure;

FIG. 14C depicts a second side elevation view of the aircraft interiormodular system of FIG. 14A, further illustrating the electrical andlighting system thereof, in accordance with the subject matter of thepresent disclosure;

FIG. 14D depicts a front, enlarged partial sectional view of a portionof the aircraft interior modular system of FIG. 14A, furtherillustrating the electrical and lighting system thereof, in accordancewith the subject matter of the present disclosure;

FIG. 15A depicts a first side elevation view of a surface panel for usein association with the aircraft interior modular system shown in FIG.1, in accordance with the subject matter of the present disclosure;

FIG. 15B depicts a second side elevation view of a surface panel for usein association with the aircraft interior modular system shown in FIG.1, in accordance with the subject matter of the present disclosure;

FIG. 15C depicts a partial sectional side elevation view of the aircraftinterior modular system shown in FIG. 1, further depicting an embodimentof surface panel and attachment means therefor, in accordance with thesubject matter of the present disclosure; and

FIG. 15D depicts a partial rear elevation view of the surface panel andattachment means therefor depicted in FIG. 15C for use in associationwith the aircraft interior modular system shown in FIG. 1, in accordancewith the subject matter of the present disclosure.

It is to be noted that the drawings presented are intended solely forthe purpose of illustration and that they are, therefore, neitherdesired nor intended to limit the subject matter of the presentdisclosure to any or all of the exact details of construction shown,except insofar as they may be deemed essential to the claimed subjectmatter.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In describing the several embodiments illustrated in the Figures,specific terminology is employed for the sake of clarity. The invention,however, is not intended to be limited to the specific terminology soselected, and it is to be understood that each specific element includesall technical equivalents that operate in a similar manner to accomplisha similar purpose. Additionally, in the Figures, like reference numeralsshall be used to designate corresponding parts throughout the severalFigures.

Headings are provided for the convenience and guidance of the reader.They are not intended, nor should they be construed, to be limiting inview of the various and varying embodiments of the subject matter of thepresent disclosure, whether such subject matter is found under aparticular heading or elsewhere in the Specification and/or Figures.

The present disclosure relates to mechanical structures, includingmodular structures, intended to support or resist loads. As wasdiscussed at the outset, in many applications, such mechanicalstructures—and specifically, modular structures—suffer from a variety ofdeficiencies inherent to their prevalent, box-like forms. The subjectmatter of the present disclosure is intended to offer, where appropriateto the particular application, a far superior solution to the use ofsuch box-like forms.

1. Overview

Accordingly, an exemplary embodiment demonstrating at least a portion ofthe subject matter of the present disclosure may be seen with referenceto FIGS. 1-3, wherein is shown aircraft interior modular system(sometimes hereinafter, “AIMS”) 100 taking the form of cabinetry-likestructure for installation within an aircraft galley. AIMS 100 is seen,generally, to comprise a form wherein a plurality of structural members110, most often parallel to one another, form spaced-apart layers.Clamping force, applied in some embodiments approximatelyperpendicularly to a face of each structural member 110 (sometimeshereinafter, a “layer” or “layers”) through use of one or more tensionassembly 120 comprising a cable, rope, wire, tension rod 130, or thelike, in association with one or more tubular spacer 140 (sometimeshereinafter called an “offset tube”), is used to draw structural members110 into alignment and to provide structural integrity of the AIMS 100modular construct.

A plurality of guiding offset rests 150 (sometimes hereinafter called a“GOR” or “GORs”) allows modular substructures, such as cradle assembly160, to nest into, or to be otherwise held by and/or within, AIMS 100.Cradle assembly 160, like the overall AIMS 100, comprises a plurality ofstructural members 162, most often parallel to one another, formingspaced-apart layers. Clamping force, applied in some embodimentsapproximately perpendicularly to a face of each structural member 162(sometimes hereinafter, a “layer” or “layers”) of cradle assembly 160through use of one or more tension assembly 164 comprising a cable,rope, wire, tension rod 166, or the like, in association with one ormore tubular spacer 168 (sometimes hereinafter called an “offset tube”),is used to draw structural members 162 into alignment and to providestructural integrity of modular cradle assembly 160 construct.

AIMS 100 may carry one or more appliance mount 170, similarlyconstructed in layered, tensile-constrained form. AIMS 100 may furthercarry one or more upper drawer assembly 180 and/or lower drawer assembly190 (or, in some embodiments, storage assembly 190), also similarlyconstructed in layered and tensile-constrained form. Additionally, AIMS100 may be configured so as to removably clasp and hold items, such asglassware or stemware 200, through the use of sliding retaining layers210. Upper drawer 180 and/or lower drawer or storage assembly 190preferably operate on slide rail assemblies 185, 195. Drawer 180 may beconfigured so as to support and carry any of a variety of tableware ordishware 188, flatware, serving pieces, and the like. Similarly, storageassembly may be configured to support and carry, for example, winebottles, drink containers, and a variety of foodstuffs.

In some embodiments, selected layers 220 may be electrically connectedto and energized by transformer 230 to provide electrical power forlight features 240, appliances 250, equipment, or the like. In someembodiments, transformer 230 may comprise a 300 watt, 12 volttransformer; however, it will be appreciated that transformer 230 may beselected and/or specified so as to meet the electrical requirements of aparticular modular system constructed according to the presentdisclosure.

Appropriate structural mounts 260 may be provided in order to removablyaffix AIMS 100 to a floor, subfloor, footing, rail system, wall, orother support or structural interface, such as interface 270. In someembodiments, structural mounts 260 may be disposed and attached at oneend thereof to rail or rod system 280 within interface 270. An oppositeend of structural mounts 260 may rotate over and hook onto, or (in someembodiments) into, tension rod 130. Following tightening of tensionassembly 120, structural mounts 260 function so as to hold AIMS 100 tosupport or structural interface 270, via, for example, rail or rodsystem 280.

In some embodiments, individual layers 110, 162, and the like, may befinished—in the case of aluminum material layers, for example—byuniquely colored anodize coatings in order to aid identification ofparts and rapid assembly thereof. That is to say, in some embodiments,different or differing colors may be applied to different parts of AIMS100 in order to aid identification of parts and rapid assembly thereof.Surface finishes may be applied in the form of snapped, clamped,magnetically or electro-magnetically attached, or press-fit outer layers280, or skins, that are easily removable and replaceable.

Uniquely, all assemblies, subassemblies, and components are designed andconfigured to be easily assembled, tightened, loosened, anddisassembled, both by module and by individual component, through adistinctive, single side access system, which, in most embodiments,requires use of only a single, modest tool, or minimal tools.

Now, turning attention to FIGS. 4-15, selected portions of the subjectmatter of the present disclosure will be further and more particularlydescribed.

2. Tension Assemblies and Guiding Offset Rests

In FIG. 4, tension assembly 120 is shown in greater detail. Tension rod130 traverses AIMS 100 from tension cap 132, shown in this embodiment onthe right, to terminating end 134, shown in this embodiment on the left.Tension rod 130 may be attached to tension cap 132 via means such as pin136, although other means of attachment may be utilized in anappropriate embodiment. Tension rod 130 may carry external threads 138on an end thereof, so as to cooperatively engage terminating end 134,which may carry internal threads 139 therewithin for such purposes. Atleast a portion of terminating end 134 is preferably engaged within aleftmost structural member 110 so as to prevent rotation and/ordislodgement of terminating end 134 during interaction with tension rod130.

Tension rod 130 can be seen to traverse each of a plurality ofstructural members 110. Tension rod 130 further passes through aplurality of offset tubes 140. Offset tubes 140 are disposedapproximately perpendicular to a face of each so-engaged structuralmember 110, and they bridge and space-apart each structural member 110.It can be seen that, when tension rod 130 is tightened via tension cap132, it threads into terminating end 134, and a tensile force isestablished therewithin. Tension rod 130 thereby acts to apply acorresponding compression force to each engaged structural member 110,which members are, in the embodiment of FIG. 4, the leftmost andrightmost structural members 110. This compression force is, in-turn,transmitted via each associated offset tube 140 to each succeedingstructural member 110. Accordingly, such configuration acts to drawstructural members 110 into alignment and to provide the requiredstructural rigidity and integrity of the AIMS 100 modular construct.

In some embodiments, internal offset tube retainer 142 may be fitwithin, and/or between, one or more offset tube 140 in order to betterconstrain and orient tension rod 130. Internal offset tube retainer 142may act to center and to uniformly guide tension rod 130 through andacross the AIMS 100 structure. It may further act to reduce bending oftension rod 130 during assembly and reduce vibration.

In some embodiments, bushing 144 may be fit within one or morestructural member 110. Similar in function to internal offset tuberetainer 142, bushing 144 may aid in better constraining and orientingtension rod 130; likewise, centrally and uniformly guiding tension rod130 through and across the AIMS 100 structure. Bushing 144 may furtheract to reduce bending of tension rod 130 during assembly and reducevibration.

Importantly, guiding offset rests, or GORs, 150 are fit in appropriatelocations between selected ones of offset tubes 140. Best seen withreference to FIGS. 5A and 5B, GORs 150 are preferably round, metallicretainers, comprising flat face 152 on one side and boss 154 on a secondside. Central hole 156 passes through GOR 150, with flat face 152 andboss 154 approximately concentric therewith. Flat face 152 is preferablytapered or chamfered toward the side of GOR 150 carrying boss 154 forpurposes that will be described below.

With continuing reference to FIGS. 1 and 4, it can be seen that centralhole 156 permits tension rod 130 to pass through GORs 150. Boss 154 fitswithin offset tube 140, the tubular end thereof bearing against flatsurface 159. As described in greater detail hereinbelow, tension rod 130also passes through an aligned clearance hole (see, e.g., FIG. 8C)within each structural member 110, such that, when fully assembled, alower portion of face 152 of each GOR 150 bears against structuralmember 110. So configured, and with reference to FIGS. 5C and 5D, it canbe seen that mounting tabs 163 a, 163 b, 163 c of structural member 162of cradle assembly 160 fit between an upper portion of flat faces 152 oftwo confronting GORs 150 and rest against associated portions of GOR150, structural member 110, and/or the tension rod. Structural member162 is urged into position and alignment between flat faces 152 bytapered or chamfered surfaces 158. When tension rod 130 is tightened,compression force is transferred through tension assembly 120 andstructural members 110, all as described hereinabove. GORs 150, in turn,provide corresponding compression force to structural members 162,through mounting tabs 163 a, 163 b, 163 c, drawing structural members162 into appropriate alignment with the AIMS 100 structure, andproviding the required structural rigidity and integrity of cradleassembly 160 within the AIMS 100 modular construct. Thus, GORs 150 allowmodular substructures, such as cradle assembly 160, to interface with,and be removably held within, AIMS 100, all as described in greaterdetail hereinbelow.

Returning to FIG. 4, further shown therein is tension assembly 164.Tension assembly 164, operating in association with cradle assembly 160,comprises equivalent component parts—and functions much the same way—asdoes tension assembly 120, operating in association with AIMS 100.Advantageously, through use of tension assembly 164, modularsubstructures, such as cradle assembly 160, can be formed withequivalent construction, attributes, and properties as the larger,carrying structure, in this example, AIMS 100. Accordingly, each modularsubstructure and/or subassembly easily can be manufactured and assembledin the preferred, layered form described herein, with all of theassociated features, conveniences, advantages, and benefits.

In some embodiments of the subject matter of the present disclosure,such as those carrying appliance mount 170, tension rod 166 may beformed with one or more shoulder 167 falling off to smaller-diameterportion 169 of tension rod 166. As will be described in greater detailhereinbelow with reference to FIGS. 7A and 7B, when tension rod 166 isloosened, shoulder 167 is drawn rightwardly (in the embodiment of FIGS.1-4). When operable in association with an appliance mount 170 brackethaving appropriate constraint and clearance configuration,smaller-diameter portion 169 of tension rod 166 meets the bracket andenables the appliance to be removed from the structure of AIMS 100.

Turning next to FIGS. 6A and 6B, an alternate embodiment of a tensionassembly according to the subject matter of the present disclosure isshown. FIG. 6A depicts tension assembly 320 in a released position;whereas, FIG. 6B depicts tension assembly 320 in a locked position. Asshown in FIGS. 6A and 6B, tension assembly 320 corresponds most closelyin form, placement, and function to tension assembly 120; however, itwill be appreciated that tension assembly 320 may be configured, asappropriate to the circumstances and need, for operation within anassembly, such as AIMS 100, a subassembly, such as cradle assembly 160,or any other appropriate modular construct formed in accordance with thesubject matter of the present disclosure.

Tension assembly 320 comprises variable diameter tension rod 322(sometimes hereinafter, a “VTR”) which traverses AIMS 100 from tensioncap 324, shown in this embodiment on the right, to terminating end 326,shown in this embodiment on the left. It may be seen that variablediameter tension rod 322 comprises regions in which its typical outsidediameter 328 smoothly necks-down to one or more minimum-diameter regions330, whereafter it smoothly necks-up to its typical outside diameter328. Variable diameter tension rod 322 may be attached to tension cap324 via means such as pin 332, although other means of attachment may beutilized in an appropriate embodiment.

Terminating end 326 engages and captures terminating dynamic offset 334.At least a portion of terminating dynamic offset 334 is engaged within aleftmost structural member 110 and terminating end 326, so as to preventrotation and/or dislodgement during interaction with VTR 322. One orboth of terminating end 326 and/or terminating dynamic offset 334 maycarry internal threads 336, so as to cooperatively engage externalthreads 338 disposed for such purposes on VTR 322. Terminating dynamicoffset 334 is formed with slot 340, which may be seen to cooperativelyengage, and interact with, slot guided rod retainer 342 associated withand carried adjacent, but inset from, a leftmost end of VTR 322. Slotguided rod retainer 342 carries pin 344 for cooperative, sliding-typeengagement with slot 340. Carried within terminating dynamic offset 334is spring 346. Spring 346 acts to bear against slot guided rod retainer342 and bias lateral motion of VTR 322.

VTR 322 can be seen to traverse each of a plurality of structuralmembers 110. VTR 322 further passes through a plurality of selectivelyarranged GORs 150 and/or offset tubes 140. Offset tubes 140 are disposedapproximately perpendicular to a face of each so-engaged structuralmember 110 and/or GOR 150, and they bridge and space-apart eachstructural member 110.

In some embodiments, external/internal offset tube retainer 348comprises outer diameter 350 approximately matching the outer diameterof offset tube 140. External/internal offset tube retainer 348 furthercomprises a boss of smaller diameter 352 approximately matching theinner diameter of offset tube 140. Accordingly, smaller diameter 352 ofexternal/internal offset tube retainer 348 may be fit within the innerdiameter of offset tube 140, so that outer diameter 350 may bear againsta face of structural member 110. In some embodiments, external/internaloffset tube retainer 348 may be formed with central hole 354 to enableVTR 322 to pass therethrough. Accordingly, external/internal offset tuberetainer 348 aids in constraining and orienting offset tubes 140 and VTR322 in association with tension assembly 320. External/internal offsettube retainer 348 may act to center and to uniformly guide VTR 322through and across the AIMS 100 structure. It may further act to reducebending of VTR 322 during assembly and to reduce vibration.

It can be seen that, when VTR 322 is tightened via tension cap 324, itthreads into one or both of terminating end 326 and/or terminatingdynamic offset 334, laterally moving slot guided rod retainer 342—whichis constrained by cooperating engagement of slot 340 and pin 344—towardterminating end 326 (leftwardly in this embodiment) and compressingspring 346. VTR 322 thereby acts to apply a compression force to eachengaged structural member 110, which members are, in the embodiment ofFIGS. 6A and 6B, the leftmost and rightmost structural members 110. Thiscompression force is, in-turn, transmitted via each associated offsettube 140 to each succeeding structural member 110. Accordingly, suchconfiguration acts to draw structural members 110 into alignment and toprovide the required structural rigidity and integrity of the AIMS 100modular construct.

As may be observed with reference to FIGS. 7A and 7B, when VTR 322 isloosened, each minimum-diameter region 330 is moved in the direction oftension cap 324 (rightwardly in this embodiment), through a distanceD_(RP) defined by release parameter RP, aided in said motion byoperation of spring 346 bearing against slot guided rod retainer 342,but constrained by cooperating engagement of slot 340 and pin 344. Whena line of release L_(R), corresponding to each minimum-diameter region330, aligns with a bracket having appropriate constraint and clearanceconfiguration, minimum-diameter region 330 of VTR 322 meets the bracketand enables release of said bracket from the structure of AIMS 100.Advantageously, spring 346 acts to bias and hold VTR 322 in anappropriate position for bracket release. Additionally, throughcooperative interaction of terminating dynamic offset 334 with spring346-biased, slot guided rod retainer 342, a user can affirmatively sensewhen tension assembly 320 is unlocked and correctly aligned for bracketrelease.

With the above-provided understanding of the construction and operationof tension rod 166, as best seen in FIG. 4, and VTR 322, as best seen inFIGS. 6A and 6B, the reader's attention is now directed to FIGS. 7A and7B. In this embodiment, mounting brackets 172 are disposed so as tocarry appliance mount 170. Mounting brackets 172 comprise variable widthslot 174. Best seen with reference to FIG. 7A, the width of slot 174 isgreater within its terminal portion 176 than within its lead-in portion178.

As was described hereinabove, tension rod 166 may be formed with one ormore shoulder 167 falling off to smaller-diameter portion 169 of tensionrod 166, all as best seen with reference to FIG. 4. Under circumstanceswherein appliance mount 170 and mounting brackets 172 are fully engagedwith tension assembly 164, and tension assembly 164 is in tightenedconfiguration, smaller diameter portion 169 of tension rod 166 isdisposed away from mounting brackets 172. Thus, larger diameter portionsof tension rod 166 are disposed within terminal portions 176 of slots174. Because these larger diameter portions of tension rod 166 cannotpass through the smaller width lead-in portions 178 of mounting brackets172, appliance mount 170 is locked firmly into place.

On the other hand, when tension rod 166 is loosened, shoulder 167 isdrawn rightwardly (in the embodiment of FIG. 7B), whereinsmaller-diameter portions 169 of tension rod 166 are then disposedwithin terminal portions 176 of slots 174. Because thesesmaller-diameter portions 169 of tension rod 166 are of sufficientlysmall cross-section to be able to pass through the smaller width lead-inportions 178 of mounting brackets 172, appliance mount 170 is unlocked.In its unlocked position, appliance mount 170 can be rotated out ofengagement with tension rod 166; and, thereafter, appliance mount 170can be removed for maintenance, reconfiguration, or the like.

It will be apparent that, in appropriate modular construct embodiments,alternate embodiment tension assembly 320, best seen with reference toFIGS. 6A and 6B, may be utilized in lieu of tension assembly 164 justdescribed. It will also be apparent that, in appropriate modularconstruct embodiments, variable diameter tension rod 322, or a modifiedversion thereof, may be substituted for tension rod 166 within tensionassembly 164.

3. Support Layer Assembly

Turning now to FIGS. 8A-8C, shown is an embodiment of AIMS 100comprising support layer assembly 400, which, in turn, comprises avariety of aspects that will now be described in greater detail.

Generally, support layer assembly 400 may be seen to comprise aplurality of support layers 110, individual ones of which are designatedin FIGS. 8A and 8C as support layers 110 a-110 i. Certain furtherdetails of construction of support layers 110 a-110 i may be seen withreference to FIGS. 8B and 8C. It is noted that, in some embodiments, ⅛″6061 aluminum alloy is used as a preferred material for support layers110.

Best seen with reference to FIG. 8A, support layers 110 a-110 i areassembled into the configuration shown, and are made structurally sound,through use of a plurality of tension assemblies such as were describedin greater detail hereinabove. For example, in the embodiment of supportlayer assembly 400 shown in FIGS. 8A-8C, tension assemblies 120 may beutilized. When support layers 110 are connected by tension assemblies120 and tension assemblies 120 are sufficiently tightened, as describedhereinabove, support layer assembly 400 is made rigid and structurallyintegral.

Accordingly, common to support layers 110 a-110 i are a plurality ofclearance holes 410. For clarity of meaning, it is here noted that inFIG. 8C, a reference to a feature in a specified number of “places”designates that said feature is present in the referenced number ofsupport layers 110 and in corresponding positional alignment. Thus, andfor example, a drawing reference to clearance hole “410 (8 places)”designates that said clearance hole 410 is present in correspondingpositional alignment within each of eight (8) layers support layers 110.In this regard, it may be seen that respective ones of clearance holes410 are mutually aligned with corresponding ones of clearance holes 410within others of support layers 110 a-110 i, so that tension rod 130 oftension assembly 120 cooperatively may pass therethrough for thepurposes described hereinabove. Certain ones of clearance holes 410 maybe of different—or differing—diameter, such as, by way of non-limitingexample, clearance holes 412, in order to accommodate features oftension assembly 120, such as tension cap 132, terminating end 134, orthe like.

Similarly, a plurality of clearance holes 414 are mutually aligned withcorresponding ones of clearance holes 414 within support layers 110a-110 i so that rod system 280 cooperatively may pass therethrough forpurposes of mounting or otherwise affixing AIMS 100 to anotherstructure, such as was described hereinabove.

Support layers 110 c and 110 h are configured so as to provideappropriate structure for support of upper drawer 180 and lower drawer190. In this regard, each slide mount support 416 provides a surfacewithin which may be disposed a plurality of upper slide mount holes 418for attachment of upper drawer slide rail assembly 185. Similarly, eachof support layers 110 c and 110 h further provide lower surface 420within which may be disposed a plurality of lower slide mount holes 422for attachment of lower drawer slide 195.

Each of support layers 110 a-110 i provide various and further featuresin order to enable cooperative interaction with cradle assembly 160 suchas has been described above. As may be seen with continuing reference toFIG. 8C, support layers 110 b, 110 e, and 110 h provide cradle rearmounting tab bearing surface 424 and cradle front mounting tab bearingsurface 426 for cooperative engagement with corresponding cradle layers,each said cradle layer respectively carrying rear mounting tab 163 a andfront mounting tab 163 b. Similarly, it may be observed that cradlemounting tab bearing surfaces 424, 426 are configured so as to provideappropriate lateral bearing surfaces for interaction with GORs 150, ashas been previously described. Similarly, support layers 110 a, 110 c,110 d, 110 f, 110 g, and 110 i provide cradle rest surfaces 428 forcooperative engagement with corresponding cradle layers, and furtherproviding appropriate lateral bearing surfaces for offset tubes 140and/or associated components of tension assembly 120.

Although the electrical and lighting system of AIMS 100 is explained ingreater detail hereinbelow with regard to FIGS. 14A-14D, within eachsupport layer 110 a-110 i is light diffusing tube clearance 430. In somesupport layers 110, such as support layers 110 d and 110 f, lowerfestoon rail electrical conductor 432 and upper festoon rail electricalconductor 434 are formed in association with, or carried by, lightdiffusing tube clearance 430. In this regard, when energized bytransformer 230, through layers 220, support layers 110 d and 110 frespectively carry electrical current to, and form an electrical circuitwith, a lower festoon rail and an upper festoon rail, to be described ingreater detail hereinbelow, whereupon light features 240 may beactivated.

4. Cradle Layer Assembly

Turning now to FIGS. 9A-9C, shown is an embodiment of AIMS 100comprising cradle layer assembly 500. Cradle layer assembly 500 forms astructural framework for cradle assembly 160, which is configured, aswill be described in further detail hereinbelow, to cooperatively fitwithin and engage support layer assembly 400. Cradle layer assembly 500further comprises a variety of aspects that will now be described ingreater detail.

The reader will now have an appreciation for the layered construction ofAIMS 100, wherein the plurality of support layers 110 a-110 i forming,in part, support layer assembly 400 have corresponding ones of supportlayers 162 a-162 i forming, in part, cradle layer assembly 500.Generally, cradle layer assembly 500 may be seen to comprise a pluralityof cradle layers 162, individual ones of which are designated in FIGS.9A and 9C as cradle layers 162 a-162 i. Certain further details ofconstruction of cradle layers 162 a-162 i may be seen with reference toFIGS. 9B and 9C. It is noted that, in some embodiments, ⅛″ 6061 aluminumalloy is used as a preferred material for cradle layers 162.

Best seen with reference to FIG. 9A, cradle layers 162 a-162 i areassembled into the configuration shown, and are made structurally sound,through use of a plurality of tension assemblies such as were describedin greater detail hereinabove. For example, in the embodiment of cradlelayer assembly 500 shown in FIGS. 9A-9C, tension assemblies 164 may beutilized. When cradle layers 162 are connected by tension assemblies 164and tension assemblies 164 are sufficiently tightened, as describedhereinabove, cradle layer assembly 500 is made rigid and structurallyintegral.

Accordingly, common to cradle layers 162 a-162 i are a plurality ofclearance holes 510. For clarity of meaning, it is here noted that inFIG. 9C, a reference to a feature in a specified number of “places” or“pl” designates that said feature is present in the referenced number ofcradle layers 162 and in corresponding positional alignment. Thus, andfor example, a drawing reference to clearance hole “510 (8 places)” or“510 (8 pl)” designates that said clearance hole 510 is present incorresponding positional alignment within each of eight (8) cradlelayers 162. In this regard, it may be seen that respective ones ofclearance holes 510 are mutually aligned with corresponding ones ofclearance holes 510 within others of support layers 162 a-162 i, so thattension rod 166 of tension assembly 164 cooperatively may passtherethrough for the purposes described hereinabove. Certain ones ofclearance holes 510 may be of different—or differing—diameter, such as,by way of non-limiting example, clearance holes 512, in order toaccommodate features of tension assembly 164, such as tension cap 132,terminating end 134, or the like.

It may be observed that cradle layers 162 are configured so that regionssurrounding clearance holes 510, 512 act to provide appropriate lateralbearing surfaces for interaction with GORs 150, as has been previouslydescribed, and further provide appropriate lateral bearing surfaces foroffset tubes 140 and/or associated components of tension assembly 164.

Each of cradle layers 162 a-162 i provide various and further featuresin order to enable cooperative interaction with support layer assembly400, such as have been described above. As may be seen with continuingreference to FIG. 9C, cradle layers 162 b, 162 e, and 162 h carry rearmounting tab 163 a and front mounting tab 163 b for cooperativeengagement with cradle rear mounting tab bearing surface 424 and cradlefront mounting tab bearing surface 426, respectively, of correspondingsupport layers 110 b, 110 e, and 110 h. As has been previouslydescribed, support layers 110 a, 110 c, 110 d, 110 f, 110 g, and 110 iprovide cradle rest surfaces 428 for cooperative engagement withcurvature 528 of corresponding cradle layers 162 a, 162 c, 162 d, 162 f,162 g, and 162 i.

Although the electrical and lighting system of AIMS 100 is explained ingreater detail hereinbelow with regard to FIGS. 14A-14D, within eachcradle layer 162 a-162 i is light diffusing tube clearance 530. In somecradle layers 162, such as cradle layers 162 d and 162 f, lower festoonrail electrical conductor 532 and upper festoon rail electricalconductor 534 are formed in association with, or carried by, lightdiffusing tube clearance 530. In this regard, when energized bytransformer 230, through layers 220 and support layers 110 d and 110 f,cradle layers 162 d and 162 f, respectively, carry electrical currentto, and form an electrical circuit with, a lower festoon rail and anupper festoon rail, to be described in greater detail hereinbelow,whereupon light features 240 may be activated.

It was mentioned above that AIMS 100 may be configured so as toremovably clasp and hold items, such as glassware or stemware 200,through the use of sliding retaining layer 210, such as may now be seento be associated with cradle layer assembly 500. Accordingly, and withcontinuing reference to FIG. 9C, it may be seen that cradle layer 162 imay be provided with features 536, configured in ring-like form in theembodiment shown, for cooperatively supporting and holding the feet of aselect number of stemware 200. Cradle layer 162 h may be provided withfeatures 538, configured in arm-like form in the embodiment shown, forcooperatively supporting and holding the stems of a select number ofstemware 200. And cradle layer 162 g may be provided with features 540,configured in C-shaped form in the embodiment shown, for cooperativelysupporting and holding the rim or bowl portions of a select number ofstemware 200. For example, in the embodiment of FIGS. 9A-9C, cradlelayer assembly 500 is configured to removably clasp and hold six (6)pieces of stemware 200, such as wine glasses, champagne flutes, or thelike. It further may be seen that sliding retainer layer 210 may becooperatively engaged within cradle layer assembly 500 between cradlelayers 162 g and 162 f. In such configuration, retainer layer 210 actsas an end cap or end plate adjacent to, or abutting, stemware 200 rimsin order to prevent stemware 200 from vibrating and/or disengaging fromcradle layer assembly 500 during transit. As will be described ingreater detail hereinbelow, retainer layer 210 may be moved laterallyaway from the rims of stemware 200 in order to provide sufficientclearance for removal of selected pieces of stemware 200, and moved backinto adjacent or abutting position to prevent vibration and/ordisengagement of the remainder.

Similarly, cradle layers 162 a and 162 e may be configured with X-shapedstructures 542 for constraining lateral motion of appliance mount 170,and/or for matching and aligning with equivalent features encompassedwithin adjacent end layers of appliance mount 170. It will beappreciated that holes or openings 544 may be provided to lighten cradlelayers 162 a and 162 e, as preferred and/or required.

5. Sliding Retaining Layer

Turning now to FIGS. 10A-10C, shown is an embodiment of AIMS 100comprising cradle assembly 160. It was described above that, in order toremovably clasp and hold items, such as glassware or stemware 200,sliding retaining layer 210 may be cooperatively engaged within cradlelayer assembly 500 between cradle layers 162 g and 162 f.

Best seen with reference to FIG. 10B, sliding retaining layer 210 may beprovided with holes 610. As may be seen with continuing reference toFIG. 10A, holes 610 are cooperatively engaged with gliding mountingsleeves 620. Gliding mounting sleeves 620 are similarly disposed betweencradle layers 162 g and 162 f and are configured in size and dimensionto be able to laterally traverse corresponding ones of offset tubes 140.

Sliding retaining layer 210 also may be provided with internal glassretainers 630. Internal glass retainers 630 are configured so as to fitwithin, and so as to further support from the interior, the rims ofstemware 200 when sliding retaining layer 210 is brought into adjacentor abutting configuration with stemware 200 rims.

Accordingly, when a user wishes to ensure that stemware 200 is firmlyclasped into position, through lateral motion of gliding mountingsleeves 620, sliding retaining layer 210 and internal glass retainers630 may be brought into adjacent or abutting configuration with stemware200 rims in order to prevent stemware 200 from vibrating and/ordisengaging from cradle layer assembly 500 during transit. When a userwishes to release stemware 200 from clasped position, through lateralmotion of gliding mounting sleeves 620, sliding retaining layer 210 andinternal glass retainers 630 may be moved laterally away from the rimsof stemware 200 in order to provide sufficient clearance for removal ofselected pieces of stemware 200, and subsequently moved back intoadjacent or abutting position, as described, in order to preventvibration and/or disengagement of the remainder.

6. Upper Drawer Assembly

Turning now to an upper drawer assembly demonstrated within AIMS 100,FIGS. 11A-11C depict support layer assembly 400 in cooperativeassociation with upper drawer assembly 180. As depicted in FIGS. 8A-8C,support layer assembly 400 comprises support layers 110 a-110 i.Corresponding to each support layer 110 b-110 i is a respective upperdrawer layer 710 b-710 i, which is best seen with reference to FIG. 11C.It will be noted that FIG. 11C depicts each upper drawer layer 710 b-710i in closed position within its corresponding support layer 110 b-110 i.Therebelow, FIG. 11C further depicts the details of construction of eachreferenced upper drawer layer 710 b-710 i.

It will be appreciated that, like support layers 110 and cradle layers162, each upper drawer layer 710 b-710 i is configured for a purposespecific to its location within upper drawer assembly 180. For example,each of upper drawer layers 710 b-710 i are configured with a pluralityof holes 712 allowing them to be joined together in modular form viatension assemblies analogous to those detailed hereinabove; to wit, viaappropriately scaled tension rods, offset tubes, and like componentparts, as may be required.

In the embodiment shown, upper drawer layers 710 c and 710 h are furtherconfigured with a plurality of holes 714, in cooperative location withslide mount holes 418 within corresponding support layers 110 c and 110h. Such configuration enables attachment of drawer slide rail assemblies185 to upper drawer layers 710 c and 710 h, as will be described ingreater detail below.

Upper drawer layers 710 e and 710 f may be configured with tableware ordishware 188 support rack 716. Best seen with reference to FIG. 11A,support rack 716 may enable convenient and organized arrangement andstorage of, and user access to, tableware or dishware 188, flatware,serving pieces, and/or the like, disposed within upper drawer assembly180.

Upper drawer slide rail assemblies 185 are affixed to support layers 110a and 110 h via slide mount holes 418 in the referenced support layers.Upper drawer assembly 180 is affixed on a first side via layer 710 c toa first drawer slide rail assembly 185 associated with support layer 110c. Upper drawer assembly 180 is affixed on a second side via layer 710 hto a second drawer slide rail assembly 185 associated with support layer110 h. In this configuration, upper drawer assembly 180 is operablebetween an open and a closed position, best seen with reference to FIGS.11A and 11B.

It is noted that finishing layers optionally may be applied and/oraffixed to appropriate ones of upper drawer layers 710 b, 710 i, frontface 718 of upper drawer assembly 180, and/or the like, in order toprovide a pleasing aesthetic surface matching that of other portions ofAIMS 100, as will be further detailed below.

7. Lower Drawer Assembly

Turning now to a lower drawer assembly demonstrated within AIMS 100,FIGS. 12A-12C depict support layer assembly 400 in cooperativeassociation with lower drawer assembly 190. As depicted in FIGS. 8A-8C,support layer assembly 400 comprises support layers 110 a-110 i.Corresponding to each support layer 110 b-110 i is a respective lowerdrawer layer 810 b-810 i, which is best seen with reference to FIG. 12C.It will be noted that FIG. 12C depicts the details of construction ofeach referenced lower drawer layer 810 b-810 i.

It will be appreciated that, like support layers 110 and cradle layers162, each lower drawer layer 810 b-810 i is configured for a purposespecific to its location within lower drawer assembly 190. For example,each of lower drawer layers 810 b-810 i are configured with a pluralityof holes 812 allowing them to be joined together in modular form viatension assemblies analogous to those detailed hereinabove; to wit, viaappropriately scaled tension rods, offset tubes, and like componentparts, as may be required.

In the embodiment shown, lower drawer layers 810 c and 810 g are furtherconfigured with a plurality of holes 814, in cooperative location withslide mount holes 422 within corresponding support layers 110 c and 110g. Such configuration enables attachment of drawer slide rail assemblies195 to lower drawer layers 810 c and 810 g, as will be described ingreater detail below.

Upper drawer slide rail assemblies 195 are affixed to support layers 110a and 110 g via slide mount holes 422 in the referenced support layers.Lower drawer assembly 190 is affixed on a first side via layer 810 c toa first drawer slide rail assembly 195 associated with support layer 110c. Lower drawer assembly 190 is affixed on a second side via layer 810 gto a second drawer slide rail assembly 195 associated with support layer110 g. In this configuration, lower drawer assembly 190 is operablebetween an open and a closed position, best seen with reference to FIGS.12A and 12B.

It is noted that finishing layers optionally may be applied and/oraffixed to appropriate ones of lower drawer layers 810 b, 810 i, frontface 818 of lower drawer assembly 190, and/or the like, in order toprovide a pleasing aesthetic surface matching that of other portions ofAIMS 100, as will be further detailed below. In some embodiments, eachlower drawer layer 810 b-810 i may be provided with hook-like features816 in order to accommodate such aesthetic surface or surfaces, whereinthe plurality of hook-like features 816 assembled into lower drawerassembly 190 provide slot-like functionality within which one or moreaesthetic surface may be slid into position and, thereby, captured.

8. Reconfigurable Sectional Modularity

FIGS. 13A-13D depict an embodiment of AIMS 100 comprising reconfigurablesectional modularity (“RSM”) 900. As with AIMS 100, generally, and withsupport layers 110, cradle layers 162, upper drawer layers 710, andlower drawer layers 810, specifically, reconfigurable sectionalmodularity 900 is configured in a plurality of RSM layers 910. Best seenwith reference to FIG. 13D, individual RSM layers 910 are designated,respectively, as RSM layer 910 a-910 i.

RSM 900 serves to provide a submodular mounting system, advantageouslytaking advantage of open, unutilized space(s) within extant AIMS 100structure. For example, in the embodiment of FIGS. 13A-13C, RSM 900 maybe disposed in association with cradle assembly 170 to carry a structureor device S, such as a flat panel display, an electronics panel, anelectronics module, or the like, configured at a location easily viewedby a user.

The function of reconfigurable sectional modularity 900 is to facilitaterapid reconfiguration in defined sections of a system or modularassembly. This functionality enables a user to rapidly mount, swap,reconfigure, and/or add components, structures, devices, modules, and/orthe like, that were not present in an original AIMS 100 system. For thisreason, it is noted that—unlike previously described AIMS 100 layeredmodular structures (e.g., support layers 110, cradle layers 162, upperdrawer layers 710, and lower drawer layers 810)—RSM layers 910 a-910 imay not, in some embodiments, correspond to, or align with, other AIMS100 layers. Rather, RSM 900 is configured so as to mount within AIMS100, or any aforedescribed substructure thereof, wherein there isappropriate, useful space that may logically and functionally bereconfigured to serve a higher purpose.

As with other, aforedescribed modular structures within AIMS 100, eachRSM layer 910 a-910 i is configured for a purpose specific to itslocation within AIMS 100. For example, each of RSM layers 910 a-910 iare configured with a plurality of holes 912 allowing them to be joinedtogether in modular form via tension assemblies analogous to thosedetailed hereinabove; to wit, via appropriately scaled tension rods,offset tubes, and like component parts, as may be required.

In the embodiment shown, RSM layers 910 d and 910 e are furtherconfigured with a support structure 916, configured and disposed so asto capture, support, and/or mount structure or device S within RSM 900.RSM layers 910 e and 910 f may be further configured with end portion918. In this embodiment, end portions 918 serve the purpose of abuttingrespective ends of structure or device S and, thereby, constraining anylateral motion of structure or device S within RSM 900. It will befurther appreciated that any of a variety or combination of holes and/oropenings 920 may be provided to lighten RSM layers 910, as preferredand/or required.

9. Electrical and Lighting System

Turning now to FIGS. 14A-14D, depicted is an embodiment of an electricaland lighting system for use in association with AIMS 100. Althoughcertain aspects of the electrical and lighting system previously havebeen described, further details will now be set forth.

It first should be appreciated that, other than such electrical feeds asmay supply transformer 230, AIMS 100 has no electrical wiring or wireways. The reader will recall that, in the embodiment of AIMS 100presently described, transformer 230 may comprise a 300 watt, 12 volttransformer. Accordingly, electrical current at 12 volts is conductedthrough layers of AIMS 100, as has been described hereinabove. Exemplaryof such conductive layers are support layers 110 d, 110 f and cradlelayers 162 d, 162 f.

One will recall that, within each support layer 110 a-110 i is lightdiffusing tube clearance 430. In some support layers 110, such assupport layers 110 d and 110 f, lower festoon rail electrical conductor432 and upper festoon rail electrical conductor 434 are formed inassociation with, or carried by, light diffusing tube clearance 430. Inthis regard, when energized by transformer 230, through adjacent andcontacting layers 220, support layers 110 d and 110 f respectively carryelectrical current to, and form an electrical circuit with, lowerfestoon rail 1010 and an upper festoon rail 1012, whereupon lightfeatures 240 may be activated.

Similarly, one will recall that, within each cradle layer 162 a-162 i islight diffusing tube clearance 530. In some cradle layers 162, such ascradle layers 162 d and 162 f, lower festoon rail electrical conductor532 and upper festoon rail electrical conductor 534 are formed inassociation with, or carried by, light diffusing tube clearance 530. Inthis regard, when energized by transformer 230, electrical current iscarried through layers 220 and adjacent, contacting support layers 110 dand 110 f. For clarity of illustration, it might be noted that supportlayers support layers 110 d and 110 f make principal electrical contactwith cradle layers 162 d and 162 f along contact surfaces 1018. Cradlelayers 162 d and 162 f, respectively, may then carry electrical currentto, and form an electrical circuit with, lower festoon rail 1014 andupper festoon rail 1016, whereupon light features 240 may be activated.

Turning now to FIG. 14D, certain aspects of light features 240 may beseen in greater detail. Lower festoon rail 1014 and upper festoon rail1016 are separated by festoon rail insulator 1020 Festoon-type lamps1022 are disposed between lower festoon rail 1014 and upper festoon rail1016, making electrical contact therewith via batwing festoon retainer1024. This festoon assembly is encircled by light diffusing tubes 1026.

It should also be noted that, where appropriate, bushings 144 and/orpush retainers 145 may comprise, in whole or in part, an insulatingmaterial. This, of course, is to prevent electrical current beingdirected, via tension assemblies 120, 164, from energized layers 110 d,110 f, 162 d, 162 f to other layers that are not intended to beenergized.

While the electrical system described hereinabove has been focused uponthe useful aspect of energizing light features 240, it will beappreciated that the aforedescribed method of power distribution can beapplied for powering any electrical, electronic, or lighting systemassociated with AIMS 100, including, for example, structure or device Swithin RSM 900.

10. Surface Panels, Attachment Systems, and Finishes

Turning now to FIGS. 15A-15D, disclosed are exemplary embodiments ofside and rear surface panels for use with AIMS 100. FIGS. 15A-15Dfurther depict associated attachment means for each panel.

As may be seen with reference to FIGS. 15A-15B, side panel 1110 isdisposed to fit adjacent support layer 110 a and cradle layer 162 a ofAIMS 100. Similarly, side panel 1112 is disposed to fit adjacent supportlayer 110 i and cradle layer 162 i of AIMS 100. In some embodiments,openings may be provided within side panels 1110, 1112 to accommodatelight assembly end covers 1114, 1116. Light assembly end covers 1114,1116 may be affixed, by press-fit or other known means, within sidepanels 1110, 1112. If present, light assembly end covers 1114, 1116 maybe transparent, translucent, or opaque, as deemed appropriate for theapplication and intended use.

Side panel 1110 is configured so as to be engaged with AIMS 100 bypress-fitting onto the ends of tension assemblies 120, 164. Accordingly,in some embodiments, reliefs 1118 are formed within an inside surface ofside panel 1110 in order to accommodate the outside portions ofterminating ends 134, 326, and/or other appropriate structure. Insimilar fashion, side panel 1112 is configured so as to be engaged withAIMS 100 by press-fitting onto the ends of tension assemblies 120, 164.Accordingly, in some embodiments, reliefs 1120 are formed within aninside surface of side panel 1112 in order to accommodate the outsideportions of tension caps 132, 324, and/or other appropriate structure.

So configured, side panels 1110, 1112 act to close out the AIMS systemand, further, provide a surface for appropriate aesthetic surfacetreatment. Such surface treatments may be selected from any of a varietyof known types and corresponding attachment and/or application means.For example, a wood-grained surface may be adhered, bonded, applied, orotherwise attached to an outside surface of side panels 1110, 1112 inorder to provide a finished, high-quality, cabinet-like appearance.Other surface finishes likewise may be applied or affixed, includingmetallic surfaces, laminate surfaces, faux surfaces, textile surfaces,and the like, without limitation. In some cases, side panels 1110, 1112may be finished simply with an attractively colored anodized coating,painted coating, or the like.

As may be seen with reference to FIGS. 15C-15D, in come embodiments,rear panel 1122 is disposed to fit adjacent the rearward portions ofsupport layers 110 a-110 i of AIMS 100. In view of the aforedescribed,layered construction of AIMS 100, and as advantageously provided by suchlayered construction, rear panel 1122 may be affixed to the structure ofAIMS 100 via inter-layer attachment points associated with one or moreoffset tube 140 of tension assemblies 120, 164, or other appropriatestructure.

In this regard, a plurality of ribs 1124 may be provided for affixationto an inside surface of rear panel 1122. Ribs 1124 may carry one or morehook-like portion 1126 configured and disposed to be cooperativelyattached to tension assembly 120. Ribs 1124 further may carry one ormore clasp 1128 configured and disposed to be cooperatively attached totension assembly 164. In some embodiments, clasp 1128 may be configuredto operate in fashion similar to that of a conventional carabineer,wherein keeper portion 1129 may operate assure that rear panel 1122 isfirmly locked in position until it is affirmatively released by a user.In some embodiments, rubber bushings 1130 may be provided in associationwith rib 1124 and clasp 1128 in order to assure that clasps 1128 areappropriately tensioned when engaged with AIMS 100. In some embodiments,one or more of clasp 1128 may be configured with relief 1132. As maybest be seen with reference to FIG. 15C, relief 1132 may provideclearance for structures, such as RSM 900, that might otherwiseinterfere with correct attachment of rear panel 1122 to AIMS 100.

Like side panels 1110, 1112, rear panel 1122 acts to close out the AIMSsystem and, further, provides a surface for appropriate aestheticsurface treatment. Such surface treatments may be selected from any of avariety of known types and corresponding attachment and/or applicationmeans. For example, a wood-grained surface may be adhered, bonded,applied, or otherwise attached to an outside surface of rear panels 1122in order to provide a finished, high-quality, cabinet-like appearance.Other surface finishes likewise may be applied or affixed, includingmetallic surfaces, laminate surfaces, faux surfaces, textile surfaces,and the like, without limitation. In some cases, rear panel 1122 may befinished simply with an attractively colored anodized coating, paintedcoating, or the like.

Although representative attachment means for panels 1110, 1112, and 1122have been described in detail hereinabove, it will be apparent to one ofordinary skill in the art that other equally sufficient attachment meansmay be utilized without departing from the scope and spirit of theaforedescribed attachment systems.

11. Single Side Access

As may now be seen from the detailed disclosure set forth above, AIMS100 advantageously may be entirely constructed, maintained, and/orreconfigured from a single side. This is the case due to the layeredstructure and design of AIMS 100, in association with its tensionassembly-based, layer-interconnection means. Accordingly, layers withineach assembly and/or subassembly are assembled in defined order inassociation with a relevant tension assembly 120, 164. Upon completionof assembly, tension assembly 120, 164 conveniently may be tightenedfrom a single side of AIMS 100, as described above, preferably makinguse of a single tool, such as a wrench. In some embodiments, atorque-measuring wrench may be utilized to assure that AIMS 100 meetsany predefined, applicable performance specifications.

Further, and importantly, should any maintenance and/or reconfigurationof AIMS 100 be required, a technician need simply loosen tensionassemblies 120, 164 from a single side of AIMS 100, and subsequentlyremove only those component parts necessary to access the layer orfeature of interest. The technician may then repair, maintain, replace,reconfigure, and/or the like, those component parts of interest;thereafter, replacing subsequent component parts in defined order inassociation with a relevant tension assembly 120, 164. Upon completionof reassembly, relevant tension assemblies 120, 164 may be retightenedfrom a single side of AIMS 100, as described.

The power of the layered construction, single side access designapproach further may be seen in considering interaction of cradleassembly 160, RSM 900, and the like, with support layer assembly 400.Should it be required to remove cradle assembly 160 from AIMS 100, atechnician need simply loosen tension assemblies 120, rotate cradleassembly 160 outwardly from AIMS 100, and lift cradle assembly 160 outof association with support layer assembly 400 and AIMS 100. Toreinstall cradle assembly 160, one simply reverses the process, aided byoperation of cradle mounting tabs 163, GORs 150, and tension assemblies120, as previously described.

Similarly, should it be required to remove RSM 900 from AIMS 100, atechnician need only loosen those component parts necessary to accessRSM 900 and, thereafter, to slide it from within AIMS 100. One needmerely reverse the process to reinstall RSM 900 into AIMS 100.

The same principal applies with regard to interaction of appliance mount170 with cradle assembly 160. Should it be required to remove appliancemount 170 from cradle assembly 160 of AIMS 100, a technician need simplyloosen tension assemblies 164, rotate appliance mount 170 outwardly fromcradle assembly 160, and lift appliance mount 170 out of associationwith cradle assembly 160 and AIMS 100. To reinstall appliance mount 170,one simply reverses the process, as described above, aided by operationof slot 174, appliance mount lower feet/tabs, GORs 150, and tensionassemblies 164.

Although it will be appreciated that, in many embodiments of the presentsubject matter, single side access will be a preferred configuration andmethod of construction, application of the present subject matter doesnot demand it. Rather, the present subject matter contemplates—andaccommodates—use of dual-side, multi-side, forward-facing, rear-facing,and other access configurations and methods of construction for systemsaccording to the present disclosure.

12. Other Considerations

Uniquely, and further advantageously, in some embodiments, AIMS 100 maytake a curvilinear form very different from conventional, rectilinearmodular constructs. In appropriate applications, tension rods 130, 166within tension assemblies 120, 164 may be replaced with one or morebendable or flexible cable, rope, wire, flexible rod, magnet,electro-magnet, or the like. In association with appropriately shapedand configured spacers, structural members, and component parts, whentension is applied via such flexible tension assemblies, thespaced-apart structural members may be drawn into alignment and held intightly clamped, curvilinear configuration around a bend.

Similarly, in some embodiments, it will be appreciated that in somemodular constructs according to the present subject matter, clampingforce may be applied vertically, horizontally, and/or diagonally, as maybe helpful, prudent, and/or required to meet the intended application.

With regard to human-factor considerations, by virtue of itsadvantageous, layered structure, AIMS 100 may be configured so as toprovide greater clearance for a user's hips and shoulders than can ofteneasily be obtained with conventional, rectangular modular designs andconstruction techniques. As may be seen in the various figures, thevarious AIMS 100 layers may be curved and shaped as may be required foroptimal space, user comfort, and convenience, all without sacrificingfunctionality, strength of the structure, or strength of any attachmentinterface.

In some applications, such as within the aircraft industry, individualparts must be permanently markable, and marked, with identifying indiciasufficient to provide manufacturing traceability in the event of anin-air/in-service accident. Accordingly, in some embodiments of AIMS100, individual parts may be permanently stamped, engraved, providedwith a distinctive pattern, provided with associated or integralelectronic tracking means, or otherwise marked with indicia, or providedwith other appropriate means, for identification. Parts may be marked,for example, by metal stamping, by engraving, with fireproof, indelibleink, or the like. In some embodiments, parts may be provided withelectronic identification means, such as electronic tracking chips, RFIDtags, signal emitting chips, and/or the like. So marked and/oridentified, in the event of a catastrophic failure or in-air/in-serviceaccident, any parts recovered may be identified and traced to origin, asmay be required by the investigative process.

13. Associated Processes for Cutting. Configuring, and Assembling

When utilizing the features and attributes attendant AIMS 100, such ashave been described herein, a designer can evaluate the space available,the functional requirements for use of that space, the highest, best,and most optimal configuration for that space, amongst otherconsiderations, and provide an aesthetically pleasing, functionally andergonomically superior configuration of modular structure that cannot beachieved by conventional methods. The layered design and construction ofAIMS 100, and related modular systems, take best advantage of modern,high speed computer aided design and computer numerically controlledmachinery. Parts are quickly and easily cut, identified, finished,inventoried (if desired), and the like. They can be picked and kittedfrom inventory, provided with assembly instructions, and quicklyassembled through use of a single, modest tool, or minimal tools. Ifdesired, parts can be packaged in flat crates, shipped wherever needed,and easily assembled in situ as could not easily be done with prior artmethods.

When it comes time to maintain, modify, or reconfigure a modularstructure according to the present disclosure, a designer may evaluatethe space available, the functional requirements for use of that space,the highest, best, and most optimal configuration for that space,amongst other considerations, and redesign only those layers, componentparts, and aspects/attributes of the modular structure as may benecessary. To effectuate the new, reconfigured, and/or modified design,one need disassemble only that which is necessary, and rebuild outwardlyfrom that layer.

Advantageously, the modular construction provided by the presentdisclosure allows for convenient, inexpensive, and quick substitution ofcomponents, assemblies, and subassemblies. One may inventory any suchoutdated, obsoleted, limited-demand, or limited-cycle parts for eventualreuse; thereby, preserving functionality and avoiding waste. One mayprovide a catalog of modular system components, subassemblies, and thelike, in order to provide convenient, flexible, customizable, and/orpersonalized modular systems according to the present disclosure.

As the reader may now observe, having the benefit of the detaileddisclosures set forth above, there are several distinct advantages andbenefits attendant the layered construction so described. For example,each and every layer—of each and every structure and substructure—can beoptimized to serve exactly the purpose(s) required of that particularplanar space. Each layer can be configured optimally, so as to meet theergonomic, space, and human factors necessary at precisely thatlocation. Layers may be provided with optimized attachment pointsbetween structures. Where structurally appropriate, layers can bedesigned with open spaces, both within the specific layer and betweenadjacent layers, in order to save weight and optimize available, usefulspace. Layers, and the open spaces therewithin, can later be reusedand/or reconfigured so as to conveniently and inexpensively add ormodify functionality. Layered structures, interconnected with tensionassemblies of the sorts described, are lightweight, strong, and rigid,but they can be easily assembled and disassembled with a limited numberof simple tools. This is considered especially true for layeredstructures configured with single-side access features as have beendescribed above. These are, of course, but a few of the advantages andbenefits that may be appreciated, recognized, and realized through useof layered structures and methods as set forth in this disclosure.

As will be understood by one of ordinary skill in the art, materialsselected for use in a structure constructed according to the subjectmatter of the present disclosure may be chosen from any havingproperties acceptable to the application in which the subject matter isto be utilized. For example, particular design constraints mightestablish particular requirements or have particular design constraintsas to tensile, compression, and/or shear strength; deformation and yieldcharacteristics; temperature and other thermal characteristics; impactresistance; suitability for application of particular coatings orfinishes; and/or the like. Accordingly, in particular embodiments, onemight select materials comprising any of a variety of grades and/oralloys of aluminum, steel, titanium, brass, bronze, and/or other metals;polymers, reinforced polymers, plastics, and thermoplastics; carbonfiber composites; natural materials (e.g., wood); fibrous materials(including, e.g., KEVLAR); composites, laminates, and/or monocoques;and/or other materials, and/or appropriate combinations thereof, withoutlimitation. Essentially, any known structural, engineered or engineeringmaterial might be used in association with a selected embodimentconfigured for an appropriate application.

Accordingly, a desirable and eminently effective solution to theabove-described deficiencies in prior art modular constructs and relatedprocesses has been provided herein that allows one, in appropriatecases, to avoid the construction of box-like structures; and, thereby,to obviate their many limitations. The solution provided by the subjectmatter of the present disclosure allows a designer to specify a modularconstruct that better enables a user to gain access to, and operatewithin, particularized functional parameters, without hindrance by bulkyand space-monopolizing prior art structures.

The subject matter of the present disclosure can be seen to minimize oreliminate joinder of structural panels in conventional “L” or “T”-shapedconfigurations. The subject matter of the present disclosure alsominimizes or eliminates the need to use advanced, expensive, honeycombmaterials, while providing for use of materials having appropriatemechanical properties along length and across thickness, at the sametime minimizing the required thickness—and, therefore, the weight—ofsuch materials, and, at the end, providing a significantly stronger, yetlighter structure with conventional, relatively lower cost materials.

The subject matter of the present disclosure, further, reduces orremoves the need for use of conventional pins, fasteners, adhesives,bonding agents, edge-fill products, and the like. Of course, without theuse of conventional fasteners, the subject matter of the presentdisclosure allows a modular construct to be more rapidly assembled, witha minimal number of required tools, and without custom clamps, fixtures,and/or jigs to hold the panels in fixed and appropriate relativeorientation during the assembly process.

The subject matter of the present disclosure reduces design andproduction cycles. It reduces the need for highly-skilled assemblers. Itallows for repeatability between similar modular structures. Ifin-process error or damage should occur, a modular structure accordingto the present invention may be easily and inexpensively repaired.Post-delivery or post-hoc reconfiguration and modification can moreeasily be handled, and with significantly less expense and downtime.Importantly, the subject matter of the present disclosure allowsconvenient and relatively inexpensive transportation of unassembledcomponents of a modular construct to a desired location, whereafter themodular structure can be efficiently assembled in-situ or on-site;thereby, minimizing or avoiding extended out-of-service situations.

The subject matter of the present disclosure takes advantage of the manybenefits accompanying advanced, high-speed manufacturing technologies,such as precision computer numerically controlled water jet cutting,plasma cutting, laser cutting, multi-axis milling and routing, threedimensional (“3D”) printing, injection molding, and the like, whileavoiding the need for skilled, by-hand lay-up and assembly processes.

The subject matter of the present disclosure enhances, and does notdetract from, the highest and best principals of human interface designand ergonomics. Rather, modular constructs built according to thesubject matter of the present disclosure better flow into availablespaces, reducing footprint and required operating space, whilemaintaining—or increasing—operational performance, user comfort, anduser safety.

And the subject matter of the present disclosure is useful andfunctional when applied to any of a variety of applications.

Thus, the “form should always serve function” design premise—anddesirable solutions implementing it as shown in various embodiments ofthe present disclosure—can be seen to provide a paradigm shift indesign, engineering, manufacturing, fabrication, construction, assembly,and/or like processes; in turn, leading to reductions in human labor,reductions in need for the wide variety of fasteners and correspondingassembly tools, reductions in assembly, manufacturing, and relatedcosts, increases in efficiency, increases indesign-to-finished-structure speed and predictability, more efficientand improved scalability, more efficient re-purposing and reconfiguringof the structure, decreased weight, increased usable space, and likebenefits. In appropriate cases, such paradigm shift in design,manufacture, fabrication, construction, and/or assembly might providestronger constructs, improved factors of safety, reductions in failurerates, tunable rigidity, flexibility, and/or vibrational dampeningwithin the modular construct, and like benefits, due to improvements inthe way load carrying parts are used, combined, aligned, attached, andintegrated into and within the structure.

Accordingly, the many deficiencies and problems pointed-out in the priorart have been resolved, in whole or in part, by the subject matter ofthe present disclosure, as demonstrated by, and implemented within, thevarious embodiments shown herewithin.

Having thus described exemplary embodiments of the subject matter of thepresent disclosure, it is noted that the within disclosures areexemplary only and that various other alternatives, adaptations, andmodifications may be made within the scope and spirit of the presentinvention. Accordingly, the present subject matter is not limited to thespecific embodiments as illustrated herein, but is only limited by thefollowing claims.

What is claimed:
 1. A modular system comprising: a support layerassembly, said support layer assembly comprising: a plurality ofstructural members in parallel, spaced-apart relationship; a tensionassembly configured to provide clamping force approximatelyperpendicularly to a face of each structural member; said tensionassembly comprising tension means passing through each said structuralmember; said tension assembly further passing through a plurality ofspacers, each said spacer disposed between, and in endwise, abuttingrelationship with, two said structural members; terminating meansincident an end one of said plurality of structural members, saidterminating means receiving a first end of said tension means incooperative engagement therewith; tension cap means incident another endone of said plurality of structural members, said tension cap meansreceiving a second end of said tension means in cooperative engagementtherewith; said tension cap means operable with said tension means, saidstructural members, said spacers, and said terminating means to developtensile force within said tension means and corresponding compressionforce within said spacers, whereupon said plurality of structuralmembers are drawn into alignment and provide structural integrity of themodular system; and means for attaching the modular system to anadjacent structure.
 2. The modular system of claim 1 wherein saidtension means is a rod.
 3. The modular system of claim 2 wherein saidrod comprises a variable diameter portion.
 4. The modular system ofclaim 2 wherein said first end of said tension means threads into saidterminating means.
 5. The modular system of claim 4 wherein said secondend of said tension means is affixed to said tension cap means, wherebyrotation of said tension cap means acts to develop said tension forcewithin said tension means.
 6. The modular system of claim 1 wherein saidtension assembly further comprises a guiding offset rest.
 7. The modularsystem of claim 1 wherein said tension assembly further comprises aninternal offset tube retainer.
 8. The modular system of claim 1 whereinsaid tension assembly is released and tightened via single side accessmeans.
 9. The modular system of claim 1 wherein a structural layer ofsaid support layer assembly is electrically energized, and furthercomprises a lighting system powered by said electrically energizedstructural layer of said support layer assembly.
 10. The modular systemof claim 1 further comprising a cradle assembly.
 11. The modular systemof claim 1 wherein said tension means is selected from the groupconsisting of a cable, a rope, and a wire.
 12. A modular structurecomprising: a plurality of structural layers in parallel, spaced-apartrelationship; a tension assembly configured to provide clamping forceapproximately perpendicularly to a face of each structural layer; saidtension assembly comprising tension means passing through each saidstructural layer; said tension assembly further passing through aplurality of spacers, each said spacer disposed between, and in endwise,abutting relationship with, two said structural layers; terminatingmeans incident an end one of said plurality of structural layers, saidterminating means receiving a first end of said tension means incooperative engagement therewith; and tension cap means incident anotherend one of said plurality of structural layers, said tension cap meansreceiving a second end of said tension means in cooperative engagementtherewith; said tension cap means operable with said tension means, saidstructural layers, said spacers, and said terminating means to developtensile force within said tension means and corresponding compressionforce within said spacers, whereupon said plurality of structural layersare drawn into alignment and provide structural integrity of the modularstructure.
 13. The modular structure of claim 12 wherein said tensionassembly is released and tightened via single side access means.
 14. Themodular structure of claim 12 further comprising a sliding retaininglayer.
 15. The modular structure of claim 12 wherein a structural layerof said cradle assembly is electrically energized, and further comprisesa lighting system powered by said electrically energized structurallayer.
 16. The modular structure of claim 12 further comprising anappliance mount.
 17. The modular structure of claim 12 furthercomprising a drawer assembly.
 18. The modular structure of claim 12further comprising a surface panel.
 19. A layered constructioncomprising: a plurality of rigid layers in parallel, spaced-apartrelationship; a tension assembly configured to provide clamping forceapproximately perpendicularly to a face of each rigid layer; saidtension assembly comprising tension means passing through each saidrigid layer; said tension assembly further passing through a pluralityof spacers, each said spacer disposed between, and in endwise, abuttingrelationship with, two said rigid layers; terminating means incident anend one of said plurality of rigid layers, said terminating meansreceiving a first end of said tension means in cooperative engagementtherewith; and tension cap means incident another end one of saidplurality of rigid layers, said tension cap means receiving a second endof said tension means in cooperative engagement therewith; said tensioncap means operable with said tension means, said rigid layers, saidspacers, and said terminating means to develop tensile force within saidtension means and corresponding compression force within said spacers,whereupon said plurality of rigid layers are drawn into alignment andprovide structural integrity of the layered construction.
 20. Thelayered construction of claim 19 wherein said tension means is a rod,said rod optionally comprising a variable diameter portion, and whereinsaid first end of said rod threads into said terminating means, andwherein said second end of said rod is affixed to said tension capmeans, whereby rotation of said tension cap means acts to develop saidtension force within said rod.